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Home / Wheel Loaders / JCB Wheel Loaders / JCB 403 Plus |
JCB 403 Plus Troubleshooting
The
JCB 403 Plus wheel loader driveline system components: a 101.5 cu.in (1.7L)
Perkins 403J-E17T 3-cylinder turbocharged diesel engine with a rated power of 50
hp (36 kW), and 2-range hydrostatic transmission. The open center hydraulic
system has a pump with a rated capacity of 14 gal/min (53.2 l/min). The system
relief pressure is 2610 psi (180 bar). The JCB 403 Plus is equipped with a
hydraulic power steering, hydraulic wet disc brakes, and 31x15.50-15 tires. The
wheel loader has a maximum lift height of 113.4" (2880 mm) and breakout force of
3585 lbs (1630 kg). The rated operating capacity is 1783 lbs (810 kg), and
tipping load is 3565 lbs (1620 kg).
Engine Troubleshooting |
Engine difficult to start or won't start
Air in the fuel pipes - Bleed the fuel pipes.
Fuel filter plugged - Clean the filter element.
Dirty or damaged injection nozzles - Test injection nozzles and change if necessary.
Water in the fuel system - Change fuel and repair fuel system.
Valve clearance is out of adjustment - Adjustment procedure required.
Fuel injection pump damage - Repair or change injection pump.
Diesel starts and stalls immediately
Clogged air cleaner - Service or replace air cleaner.
Clogged fuel filter - Clean the filter or install new filter element.
Problems with fuel injection pump tightness - Inspect fuel injection pump for leaks.
Damaged or clogged injectors - Replace or clean fuel injectors.
Damaged fuel injection pump - Replacement or repair required.
Engine stalls during operation
Engine is cold - Normalize the temperature by warming up the engine.
Fuel filter element clogging - Replace the filter element.
Air in the fuel system - Air bleeding.
Defective injection nozzle - Service or change injection nozzles.
Timing of fuel injection pump is incorrect - Adjust according to specifications.
Engine stalling at idle
Low idle speed set incorrectly - Adjust low idle speed.
Fuel injection pump malfunction - Rebuild or install a new injection pump.
Fuel injectors are faulty or clogged - Change or clean fuel injectors.
Improper valve clearance - Adjust valve clearance according to specifications.
Loss of engine power
Plugged air filter - Clean or change filter.
Faulty fuel injection nozzles - Service or change injection nozzles.
Improper fuel injection pressure - Adjust to proper pressure.
Valve clearance is out of adjustment - Adjustment procedure required.
Low idle speed setting is not correct - Adjustment required.
Restricted fuel hoses or lines - Service fuel hoses and lines.
Damaged cylinder-head gasket - Replace cylinder head gasket.
Worn or damaged piston rings - Install new piston rings.
Engine overheating
Engine has a lack of coolant - The cooling system needs to be refilled and checked for faults.
Not enough engine oil - Fill up the oil to required level.
Defective radiator cap or clogged radiator fins - Clean radiator or replace cap.
Fan belt is loose or defective - Belt change is required.
Diesel engine overloaded - Load reducing is recommended.
Oil pressure is insufficient
Insufficient engine oil - Add oil to the engine crankcase.
Oil filter is dirty - Replace or service engine oil filter.
Different type of engine oil - Drain crankcase and refill with correct oil.
Crankshaft bearing has incorrect oil clearance - Bearing replacement required.
Oil pump malfunction - Replace as required.
Engine noise or knocking
Not enough engine oil - Need to add engine oil.
Engine is not warmed up to required temperature - Warm up to required temperature.
Wrong setting of fuel injection pump timing - Set the fuel pump timing correctly.
Incorrect low idle setting - Adjust as required.
Defective fuel injectors - Clean fuel injectors or change it.
Connecting rod is worn or not aligned - Alignment procedure or replacement is required.
Worn or broken pistons - Install new pistons.
Hydrostatic Transmission Troubleshooting |
HST transmission noises
Transmission fluid is dirty or fluid level is too low - Top up to proper level or change transmission fluid.
Speed control linkage is defective or unadjusted - Change or adjust linkage.
Relief valve is damaged - Replace the valve.
Transmission overload - Reduce transmission load.
Transmission components are damaged or worn - After disassembly and inspection, replace defective components.
Low power
Lack of transmission fluid - Fill the transmission housing to proper fluid level.
Relief valve is stuck - Replace relief valve.
Speed control linkage is defective or unadjusted - Change or adjust linkage.
Transmission oil overheating
Lack of transmission fluid - Fill the transmission housing to proper fluid level.
Clogged transmission oil filter element - Service or replace the transmission oil filter.
Plugged or defective cooling components - Check all cooling components and repair or change if required.
Transmission overload - Reduce loading.
External oil leaks
Damaged seals or gaskets - Gaskets or seal replacement required.
High internal transmission case pressure - Change defective components.
Oil return tube is plugged - Clean or replace the tube.
Hydraulics Troubleshooting |
Hydraulic system overheats
Incorrect hydraulic pressure setting - Hydraulic pressure must be set correctly.
Main relief valve improper adjustment or failure - Replace or set up the relief valve.
Hydraulic oil is dirty - Hydraulic oil change required.
Not enough hydraulic oil in the system - Fill up the hydraulic oil.
Hydraulic pump is worn - Repair or replace pump if necessary.
Boom won't lower or raise
Faulty lift controls - Inspect and repair if necessary.
Hydraulic pump failure - Repair or change pump if required.
Damaged hydraulic control valve - Install a new hydraulic valve or repair it.
Damaged hydraulic cylinder - Repair or install a new lift cylinder.
Hydraulic fluid level low - Fill up the hydraulic fluid.
Bucket is not working
Faulty bucket tilt controls - Repair or replace.
Damaged hydraulic oil pump - Repair or change pump if required.
Damaged hydraulic control valve - Install a new valve or repair it.
Bucket cylinder is faulty - Repair or install a new cylinder.
Hydraulic fluid is insufficient - Checking hydraulic fluid level and add if necessary.
Slow bucket or lift arm action
Faulty hydraulic oil pump - Check pump flow and install new pump if necessary.
Oil leaks from hydraulic cylinder - Repair leak by replacing the seals.
Hydraulic fluid is insufficient - Fill the system to proper hydraulic fluid level.
Faulty or incorrect setting hydraulic control valve - Adjust properly or repair.
Hydraulic system loosing pressure - Set pressure correctly.
Lift arm or bucket movements are jerky
Air in the hydraulic system - Bleed hydraulic system.
Hydraulic oil filter element clogging - Change or clean oil filter.
Hydraulic fluid is contaminated - The fluid must be changed.
Cylinder tube or rod is scored - Change defective component.
Hydraulic pump is excessively noisy
Hydraulic leaks or low oil level - Correct hydraulic leaks or top up oil as needed.
Hydraulic filter is clogged - Clean or change the filter.
Suction line is clogged - Need to clean the suction line.
Air enters the pump - Need to bleed air.
Faulty pump parts - Rebuild or replace hydraulic pump.
Electrical Troubleshooting |
Battery is not charging
Loose or corroded cable connections - Clean or tighten wiring connections.
Battery terminal connectors are faulty - Terminal connectors need to be changed.
Battery is defective - Change the battery.
Worn or loose belt - Replace belt or adjust belt tension.
Starter cranks slow
Low battery power - Battery needs to be recharged.
Battery runs out quickly - Battery needs to be serviced or replaced.
Disconnected wires or corroded battery terminals - Check wiring connections and replace or clean terminals.
Starter doesn't crank
Battery is drained or defective - Charge or change the battery.
Battery cables are disconnected or improperly connected - Inspect cables and connect properly.
Battery voltage is low - Recharge the battery.
Starter motor is faulty - Starter should be changed.
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WHEEL LOADERS SPECIFICATIONS |
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